ASME Go Kart Team 23-24

During the design phase, our team identified critical requirements such as a kill switch, effective braking, rider comfort, adequate speed, and structural integrity. I contributed to creating SolidWorks CAD models of the kart and its individual components, which were later assembled into a full design. To validate our concepts, we conducted finite element analyses (FEA) on the frame that demonstrated a factor of safety of five under a 160-pound driver load. Key design decisions included implementing Ackermann steering geometry for tighter turning, selecting a Predator 212cc engine with a torque converter for strong acceleration, and incorporating a hydraulic braking system for safe stopping. An open-wheel chassis made from mild steel tubing provided the strength and manufacturability needed to stay on budget. 

Testing was an essential part of the process. Initially, the kart reached only 9 miles per hour despite strong acceleration. Through troubleshooting, we discovered that the brake caliper was dragging against the axle and that the torque converter spring needed adjustment. Once corrected, the kart reached speeds of up to 28 miles per hour (governed) with smooth acceleration, stable handling, and strong braking performance. The kart ultimately achieved the fastest lap time of 25 seconds on our track, and drivers reported that it was fun, responsive, and easy to operate. 

This project provided me with valuable hands-on experience in manufacturing and mechanical engineering technology. I gained skills in machining, welding, CAD modeling, FEA validation, and 3D printing, while also developing an appreciation for budget management, iterative design, and collaborative teamwork. Our final build came in at $1,028, well under budget, and performed reliably throughout testing and competition. Looking ahead, future improvements could include the addition of suspension, bumpers, and weight distribution adjustments to enhance performance and safety.